What are the causes of malfunctions in the screw air compressor system during operation?

Analysis of the causes and solutions for malfunctions in the operation of screw air compressor systems. Now, let our editor from Hunan Ruisheng Electromechanical Equipment take you on a look at the content of Zhigao screw air compressors. Screw compressors are composed of a pair of parallel, interlocking female and male screws, and are the most widely used type of rotary compressor. There are two types of screw compressors: dry and wet. Dry refers to not spraying liquid in the working chamber; Wet type refers to injecting lubricating oil or other liquids into the working chamber to cool the compressed gas, and then removing oil or other liquid impurities from the compressed air through high-precision filters to obtain higher quality compressed gas. Dry screw structure is complex, difficult to maintain, noisy, and expensive; Wet application is the most widely used, with a simple structure, easy maintenance, and stable reliability.
　　
The screw air compressor does not have an intake and exhaust valve group during the intake process. The intake is only regulated by the opening and closing of a regulating valve. When the rotor rotates, the tooth groove space of the main and auxiliary rotors is maximized when it turns to the opening of the intake end wall. At this time, the tooth groove space of the rotor is connected to the free air of the intake port. During exhaust, all the air in the tooth groove is discharged. At the end of exhaust, the tooth groove is in a vacuum state. When it turns to the intake port, the outside air is sucked in and flows axially into the tooth groove of the main and auxiliary rotors. Screw air compressor maintenance reminder: When the air fills the entire tooth groove, the intake side end face of the rotor rotates away from the intake port of the casing, and the air between the tooth grooves is sealed.
　　
At the end of the suction process, the main and auxiliary rotors of the sealing and conveying process seal their tooth tips against the casing. At this time, the air in the tooth groove is sealed and no longer flows out, that is, the sealing process. The two rotors continue to rotate, with their tooth peaks and grooves matching at the suction end, and the matching surface gradually moving towards the exhaust end.

During the compression and injection process, the meshing surface gradually moves towards the exhaust end, that is, the gap between the meshing surface and the exhaust port gradually decreases, and the gas in the gap is gradually compressed, increasing the pressure. This is the compression process. And compression
　　
At the same time, lubricating oil is also sprayed into the compression chamber and mixed with the chamber air due to the pressure difference. 2.4 During the exhaust process, when the meshing end face of the rotor during the maintenance of the screw air compressor is connected to the exhaust of the casing (at this time, the pressure of the compressed gas is the highest), the compressed gas begins to be discharged until the meshing surface of the tooth peak and the tooth groove moves to the exhaust end face. At this time, the tooth groove space between the meshing surfaces of the two rotors and the exhaust port of the casing is zero, which completes the exhaust process. At this time, the length of the tooth groove between the meshing surface of the rotor and the intake port of the casing reaches its maximum, and the suction process continues.
　　
Analysis and Remedial Measures for Operating Faults of Screw Air Compressors: As the main equipment in the industry that provides compressed air, screw air compressors are inevitably affected by faults during operation. The following text provides a detailed explanation of their faults and solutions.
　　
Trip problem of screw air compressor: The trip problem of air compressor refers to the occurrence and tripping phenomenon of one or some reasons during its normal operation. Specifically analyzing this phenomenon, it can be found that the cause of tripping in practical operation is not unique. Generally speaking, the reason for air compressor tripping is that the temperature exceeds the upper limit of the air compressor temperature; Ventilation equipment malfunction; Low oil level; Insufficient oil pressure injected by the host; Short circuit or prolonged operation of the equipment is caused by the small cross-sectional area of the transmission line.
　　
When the air compressor trips, it often leads to a sudden drop in system pressure. Long term operation in this state may cause safety accidents in the air compressor. The tripping phenomenon is a major equipment problem in operation, therefore, when the tripping phenomenon occurs, the overall system of the air compressor should be checked and dealt with immediately. Generally speaking, common handling measures include: conducting a comprehensive troubleshooting of the cooling system to determine whether it is operating normally and effectively; Check the operation of the ventilation device and manually ventilate the air compressor room to reduce the ambient temperature during the operation of the screw air compressor; Fill the oil and gas separator with oil to ensure that its oil level is within the normal operating range; Check if there is a short circuit in the equipment circuit, replace the equipment wires if necessary, and increase the cross-sectional area of the wires to reduce heat generation; Check the filter element of the oil and gas separator. If there is any blockage, it needs to be replaced.
　　
The problem of insufficient pressure in screw air compressors: The problem of insufficient pressure in screw air compressors is usually manifested as the pressure never reaching the required mechanical pressure when the air compressor continues to work. The reasons for this malfunction are not unique, and the main reasons are as follows: the system consumes a large amount of air, which makes it impossible for the air intake speed to compensate for the consumption; When air enters, it is obstructed at the filter, usually due to blockage caused by long-term use of the air filter; The air compressor system has a large-scale air leakage fault; The filter element in the oil and gas separator may have malfunctioned.
　　
Insufficient pressure of screw air compressor will cause problems in the corresponding production process or procedure, thereby affecting the overall operation. When the screw air compressor experiences insufficient pressure, the corresponding treatment methods mainly include the following: reducing the consumption of air in the system, or introducing a new air compressor for collaborative work; Clean the air filter, remove blockages at the air filter, and ensure unobstructed air intake; Conduct a comprehensive inspection of the air compressor, with a focus on checking for any air leaks in each part. Once discovered and addressed, eliminate any air leaks; When the filter element of the oil and gas separator malfunctions, it should be replaced in a timely manner.
　　
The problem of abnormal noise in screw air compressors often occurs during operation, such as metal impact sound, uniform knocking sound, and friction whistling sound. The possible reasons for the abnormal noise of the air compressor are as follows: ① The connecting rod bearing is severely worn, the connecting rod bolt is loose, the connecting rod bushing is severely worn, and the main shaft is severely worn or damaged, resulting in impact sound; ② The belt is too loose, and the grooves of the active and passive belts do not match, causing slippage and producing abnormal noise from the air compressor; ③ The air compressor did not supply oil immediately after operation, and the metal dry friction caused abnormal noise from the air compressor; ④ Loose fixing bolts; ⑤ Loosening the tightening gear nut causes excessive backlash and produces abnormal knocking sound of the air compressor; ⑥ There is a foreign object on the top of the piston.
　　
At this point, it is necessary to troubleshoot one by one, and the troubleshooting can be carried out step by step according to the following steps until the fault is found: ① When the air compressor makes abnormal noise, check whether the connecting rod bearing, connecting rod bushing, and main bearing are worn, pulled, or burned, and whether the connecting rod bolts are loose; ② Check if the main oil passage of the air compressor is unobstructed; Suggest replacing severely worn or strained bearing shells, bushings, and main shaft bearings, tightening connecting rod bolts, and aligning the compressed air oil hole with the air compressor inlet hole; Smooth the main oil passage. When reassembling, attention should be paid to the spindle bearings; ③ Check the inlet pressure of lubricating oil and whether the oil pipeline is damaged or blocked. If the pressure is insufficient, adjust, clean, and replace the faulty pipeline immediately; Check the oil quality and impurity content of the lubricating oil, compare it with the usage standard, and replace it immediately if it exceeds the standard; Check if the air compressor is supplied with oil. If there is no oil supply, conduct a comprehensive inspection immediately; ④ Check whether the fixing bolts of the air compressor are loose and tighten them, which can help alleviate the abnormal noise of the air compressor; ⑤ Gear driven air compressors should also be checked for loose gears or gear installation fit. Loose nuts should be tightened, and those with fitting problems should be replaced; ⑥ Removing foreign objects can help alleviate the abnormal noise of the air compressor.
　　
The overheating problem of screw air compressor is mainly reflected in the high exhaust temperature of the air compressor and the overheating of the operating parts, exceeding the normal operating temperature. The main reasons for overheating are as follows: ① Failure of the pressure relief valve or unloading valve to operate leads to overheating faults in the air compressor. ② Severe leakage of the air brake system resulted in overheating of the air compressor. ③ Insufficient oil supply to the operating parts and cylinder pulling. At this point, follow the following methods to conduct a detailed inspection, identify the problem, and handle it immediately. ① Check the pressure relief valve components during intake unloading, clean and eliminate any stuck parts or replace faulty ones. When unloading the exhaust, check if the unloading valve is blocked or stuck, and clean, repair or replace the faulty parts to effectively eliminate the overheating fault of the air compressor; ② Check the brake system components and pipelines; ③ Poor lubrication between the piston and cylinder liner, insufficient clearance, or cylinder pulling can all cause overheating. In such cases, faulty parts should be inspected, repaired, or replaced.